WO2013094268A1 - Matériau de filtration pour un filtre, son procédé de fabrication, et filtre - Google Patents

Matériau de filtration pour un filtre, son procédé de fabrication, et filtre Download PDF

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Publication number
WO2013094268A1
WO2013094268A1 PCT/JP2012/074503 JP2012074503W WO2013094268A1 WO 2013094268 A1 WO2013094268 A1 WO 2013094268A1 JP 2012074503 W JP2012074503 W JP 2012074503W WO 2013094268 A1 WO2013094268 A1 WO 2013094268A1
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Prior art keywords
filter
filter medium
fiber
medium according
fibers
Prior art date
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PCT/JP2012/074503
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English (en)
Japanese (ja)
Inventor
雄一 濱田
光俊 鈴木
宏征 石井
稲垣　健治
Original Assignee
株式会社マーレ フィルターシステムズ
帝人ファイバー株式会社
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Application filed by 株式会社マーレ フィルターシステムズ, 帝人ファイバー株式会社 filed Critical 株式会社マーレ フィルターシステムズ
Priority to CN201280062717.8A priority Critical patent/CN104066491B/zh
Priority to EP12860820.5A priority patent/EP2796180B1/fr
Priority to US14/362,727 priority patent/US10550803B2/en
Publication of WO2013094268A1 publication Critical patent/WO2013094268A1/fr

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
    • F02M35/00—Combustion-air cleaners, air intakes, intake silencers, or induction systems specially adapted for, or arranged on, internal-combustion engines
    • F02M35/02—Air cleaners
    • F02M35/024—Air cleaners using filters, e.g. moistened
    • F02M35/02441—Materials or structure of filter elements, e.g. foams
    • F02M35/02458—Materials or structure of filter elements, e.g. foams consisting of multiple layers, e.g. coarse and fine filters; Coatings; Impregnations; Wet or moistened filter elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/14—Other self-supporting filtering material ; Other filtering material
    • B01D39/16—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/14—Other self-supporting filtering material ; Other filtering material
    • B01D39/16—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres
    • B01D39/1607—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous
    • B01D39/1623—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous of synthetic origin
    • B01D39/163—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous of synthetic origin sintered or bonded
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/14—Other self-supporting filtering material ; Other filtering material
    • B01D39/16—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres
    • B01D39/18—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being cellulose or derivatives thereof
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4374—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece using different kinds of webs, e.g. by layering webs
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
    • D04H1/43825—Composite fibres
    • D04H1/43828—Composite fibres sheath-core
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
    • D04H1/43825—Composite fibres
    • D04H1/4383—Composite fibres sea-island
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
    • D04H1/43835—Mixed fibres, e.g. at least two chemically different fibres or fibre blends
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
    • D04H1/43838—Ultrafine fibres, e.g. microfibres
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
    • D21H27/08—Filter paper
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
    • D21H27/30—Multi-ply
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
    • F02M35/00—Combustion-air cleaners, air intakes, intake silencers, or induction systems specially adapted for, or arranged on, internal-combustion engines
    • F02M35/02—Air cleaners
    • F02M35/024—Air cleaners using filters, e.g. moistened
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/02—Types of fibres, filaments or particles, self-supporting or supported materials
    • B01D2239/025—Types of fibres, filaments or particles, self-supporting or supported materials comprising nanofibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/06—Filter cloth, e.g. knitted, woven non-woven; self-supported material
    • B01D2239/065—More than one layer present in the filtering material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/08—Special characteristics of binders
    • B01D2239/086—Binders between particles or fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/10—Filtering material manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/12—Special parameters characterising the filtering material
    • B01D2239/1233—Fibre diameter
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
    • F02M35/00—Combustion-air cleaners, air intakes, intake silencers, or induction systems specially adapted for, or arranged on, internal-combustion engines
    • F02M35/02—Air cleaners
    • F02M35/024—Air cleaners using filters, e.g. moistened
    • F02M35/02408—Manufacturing filter elements
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
    • F02M35/00—Combustion-air cleaners, air intakes, intake silencers, or induction systems specially adapted for, or arranged on, internal-combustion engines
    • F02M35/02—Air cleaners
    • F02M35/024—Air cleaners using filters, e.g. moistened
    • F02M35/02441—Materials or structure of filter elements, e.g. foams

Definitions

  • the present invention relates to a filter medium capable of obtaining a filter having high collection efficiency, low pressure loss, and a long filter life, a method for producing the same, and a filter using the filter medium.
  • an air-laid multilayer filter medium with a gradient of fiber fineness for example, see Patent Document 1
  • a superficial layer of general-purpose nonwoven fabric laminated with ultrafine fibers obtained by electrospinning for example, Patent Document 2, Patent Reference 3
  • the air-laid multi-layer filter medium having a gradient of fiber fineness achieves a low pressure loss and a high filter life, but it is insufficient for collecting extremely fine dust.
  • the present invention has been made in view of the above background, and its object is to provide a filter medium capable of obtaining a filter having high collection efficiency, low pressure loss, and long filter life, and a method for producing the same. And providing a filter using the filter medium.
  • a filter medium for a filter made of a wet nonwoven fabric and having a multilayer structure of two or more layers in the thickness direction, between two adjacent layers of the multilayer structure It is found that the balance of pressure loss, collection efficiency and life can be obtained by gradually changing the layer structure from one layer to the other without the presence of a boundary surface. As a result, the present invention has been completed.
  • a filter medium used as a component of a filter and made of a wet nonwoven fabric the filter medium has a multilayer structure of two or more layers, and adjacent to the multilayer structure 2
  • a filter medium is provided which is characterized in that no interface exists between the layers.
  • the filter medium is made of a fiber-forming thermoplastic polymer
  • the single fiber fine diameter (D) is 100 to 1,000 nm
  • the ratio of the fiber length (L) to the single fiber fine diameter (D) (L)
  • the short-cut nanofiber is made of a fiber-forming thermoplastic polymer and has an island component having an island diameter (D) of 100 to 1,000 nm, and an alkaline aqueous solution rather than the fiber-forming thermoplastic polymer.
  • the sea component of the composite fiber having a sea component made of an easily soluble polymer is dissolved and removed.
  • the sea component is polyethylene terephthalate copolymerized with 6 to 12 mol% of 5-sodium sulfoisophthalic acid and 3 to 10 wt% of polyethylene glycol having a molecular weight of 4,000 to 12,000. Is preferred.
  • the island component is preferably polyester.
  • the number of islands is 100 or more in the composite fiber.
  • a core / sheath composite binder fiber is further contained. Further, when the delamination strength between two adjacent layers of the multilayer structure is measured by n number 10, the ratio of the maximum value / minimum value in the remaining 8 points excluding the maximum value and the minimum value is 1.5 or more.
  • the ratio of DU / DL is 0.8 or less.
  • the basis weight is preferably in the range of 30 to 300 g / m 2 .
  • the thickness is preferably in the range of 0.5 to 4.0 mm.
  • a method for producing a filter medium in which an additional slurry is added and, if necessary, the same operations as in step (2) are repeated in steps (3) and subsequent steps. Is done.
  • the filter formed using the said filter medium for filters is provided.
  • such a filter is preferably an air filter for an internal combustion engine.
  • the filter medium which can obtain the filter with high collection efficiency, low pressure loss, and a long filter lifetime, its manufacturing method, and the filter using this filter medium are obtained. It is done.
  • the filter medium of the present invention is a filter medium that is used as a filter component and is made of a wet nonwoven fabric, and the filter medium has a multilayer structure of two or more layers (preferably two layers) (that is, two layers). It is a wet nonwoven fabric obtained by using two or more slurries), and is characterized in that no boundary surface exists between two adjacent layers of the multilayer structure.
  • “the interface does not exist” means that the composition of the layer gradually changes from one layer to the other layer. If there is a boundary surface, that is, if each layer is made separately and then laminated, the density of each layer increases and the pressure loss may increase, which is not preferable. In the present invention, when the following short cut nanofibers are included, high collection efficiency is obtained, which is preferable.
  • the short cut nanofiber is made of a fiber-forming thermoplastic polymer, and has a fiber diameter (D) of 100 to 1,000 nm, preferably 300 to 800 nm, particularly preferably 550 to 800 nm, and a fiber length corresponding to the fiber diameter (D). It is preferably cut so that the ratio (L / D) of (L) is in the range of 100 to 2,500, preferably 300 to 1,500, particularly preferably 500 to 1,000.
  • the fine diameter (D) is larger than 1,000 nm, the pore diameters appearing on the wet nonwoven fabric surface may be non-uniform (that is, the ratio of the average pore diameter to the maximum pore diameter is large).
  • the fine diameter (D) is smaller than 100 nm, there is a possibility that the fine particle (D) tends to fall off from the net during paper making. Further, if the ratio (L / D) is greater than 2500, the fibers are entangled during paper making, resulting in poor dispersion. The ratio of the average pore diameter to the maximum pore diameter may be large). Conversely, if the ratio (L / D) is less than 100, the fiber-to-fiber connection becomes extremely weak, making it difficult to transition from the wire part to the blanket during the paper making process, resulting in a decrease in process stability. There is a fear.
  • the method for producing the nanofiber as described above is not particularly limited, but the method disclosed in International Publication No. 2005/095686 is preferable. That is, in terms of the fine diameter and its uniformity, the island component is made of a fiber-forming thermoplastic polymer and has an island diameter (D) of 100 to 1,000 nm, and more than the above-mentioned fiber-forming thermoplastic polymer.
  • a sea-island composite fiber also referred to as “composite fiber” in the present invention
  • composite fiber having a sea component made of an aqueous alkaline solution
  • the island diameter can be measured by photographing a cross section of the fiber with a transmission electron microscope. Moreover, when the shape of the island is an atypical cross section other than a round cross section, the diameter of the circumscribed circle is used as the island diameter (D).
  • the dissolution rate ratio of the easily soluble polymer in an aqueous alkali solution forming the sea component to the fiber-forming thermoplastic polymer forming the island component is 200 or more, preferably 300 to 3,000, Good and preferable.
  • the dissolution rate is less than 200 times, the island component of the separated fiber cross-section surface layer is dissolved because the fiber diameter is small while the sea component in the center of the fiber cross-section is dissolved.
  • the sea component at the center of the fiber cross-section cannot be completely dissolved and removed, leading to thick spots on the island component and solvent erosion of the island component itself, resulting in nanofibers with a uniform fiber diameter You may not be able to.
  • the easily soluble polymer forming the sea component include polyesters, aliphatic polyamides, and polyolefins such as polyethylene and polystyrene, which are particularly good in fiber formation.
  • specific examples include polyester polymers such as polylactic acid, ultra-high molecular weight polyalkylene oxide condensation polymer, copolymerized polyester of polyalkylene glycol compound and 5-sodium sulfoisophthalic acid as the easily soluble polymer in alkaline aqueous solution. Is the best.
  • the alkaline aqueous solution refers to an aqueous solution of an alkali metal such as potassium hydroxide or sodium hydroxide.
  • hydrocarbon solvents such as hot toluene and xylene for formic acid for aliphatic polyamides such as nylon 6 and nylon 66, trichloroethylene for polystyrene and polyethylene (especially high pressure method low density polyethylene and linear low density polyethylene)
  • hot water for polyvinyl alcohol and ethylene-modified vinyl alcohol polymers.
  • polyester polymers an intrinsic viscosity obtained by copolymerizing 6 to 12 mol% of 5-sodium sulfoisophthalic acid and 3 to 10 wt% of polyethylene glycol having a molecular weight of 4,000 to 12,000 (polyester composition at 100 ° C., 60 A polyethylene terephthalate-based copolyester having a dilute solution dissolved in orthochlorophenol per minute from a value measured using an Ubbelohde viscometer at 25 ° C.) of 0.4 to 0.6 is preferred.
  • 5-sodium sulfoisophthalic acid contributes to improving hydrophilicity and melt viscosity
  • PEG polyethylene glycol
  • PEG has a hydrophilicity increasing action that is considered to be due to its higher-order structure as the molecular weight increases.
  • the reactivity becomes poor and a blend system is produced, problems arise in terms of heat resistance and spinning stability. there is a possibility.
  • the copolymerization amount of PEG exceeds 10% by weight, there is an effect of decreasing the melt viscosity, which is not preferable.
  • polyesters are preferable examples of the poorly soluble polymer forming the island component.
  • Polyesters are particularly preferable.
  • polyesters include polyethylene terephthalate (hereinafter sometimes referred to as “PET”), polytrimethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, and the like.
  • Aromatic dicarboxylic acids whose main repeating units are, aliphatic dicarboxylic acids such as adipic acid and sebacic acid, and hydroxycarboxylic acid condensates such as ⁇ -caprolactone, diethylene glycol, trimethylene glycol, tetramethylene glycol, hexamethylene glycol, etc. A copolymer with a glycol component or the like is preferred. Of the polyamides, aliphatic polyamides such as nylon 6 and nylon 66 are preferable.
  • polyolefins are not easily attacked by acids, alkalis, etc., and have a characteristic that they can be used as binder components after being taken out as ultrafine fibers because of their relatively low melting points, such as high density polyethylene, medium density polyethylene, Preferred examples include high pressure method low density polyethylene, linear low density polyethylene, isotactic polypropylene, ethylene propylene copolymer, ethylene copolymer of vinyl monomers such as maleic anhydride, and the like.
  • the island component is not limited to a round cross section, but may be an irregular cross section.
  • polyamide polyamides have heat resistance and mechanical properties due to their high melting point, they can be used in applications that require heat resistance and strength compared to ultra-fine fibrillated fibers made of polyvinyl alcohol / polyacrylonitrile mixed spun fibers. ,preferable.
  • organic fillers such as stabilizers, light stabilizers, flame retardants, lubricants, antistatic agents, rust preventive agents, crosslinking agents, foaming agents, fluorescent agents, surface smoothing agents, surface gloss improvers, mold release improvers such as fluororesins Even if it contains an agent, it is acceptable.
  • melt viscosity of the sea component at the time of melt spinning is larger than the melt viscosity of the island component polymer.
  • the melt viscosity ratio (sea / island) is in the range of 1.1 to 2.0, especially 1.1 to 1.5. If this ratio is less than 1.1 times, the island components are likely to be joined during melt spinning, whereas if it exceeds 2.0 times, the viscosity difference is too large and the spinning tone tends to be lowered.
  • the number of islands is preferably 100 or more (more preferably 300 to 1,000).
  • the sea-island composite weight ratio (sea: island) is preferably in the range of 5:95 to 95: 5. Within such a range, the thickness of the sea component between the islands can be reduced, the sea component can be easily dissolved and removed, and the conversion of the island component into nanofibers is facilitated.
  • the proportion of the sea component exceeds 95%, the thickness of the sea component becomes too thick.
  • the proportion is less than 5%, the amount of the sea component becomes too small, and joining between islands is likely to occur. .
  • an arbitrary one such as a hollow pin group or a fine hole group for forming an island component can be used.
  • a spinneret in which a cross section of a sea island is formed by merging and compressing an island component extruded from a hollow pin or a fine hole and a sea component flow designed to fill the gap between them.
  • the discharged sea-island type composite fiber is solidified by cooling air and taken up by a rotating roller or an ejector set at a predetermined take-up speed to obtain an undrawn yarn.
  • the take-up speed is not particularly limited, but is preferably 200 to 5,000 m / min. Productivity is poor at less than 200 m / min. On the other hand, if it exceeds 5,000 m / min, the spinning stability is poor.
  • the obtained undrawn yarn may be subjected to the cutting process or the subsequent extraction process as it is, depending on the use / purpose of the ultrafine fiber obtained after extracting the sea component, or may have the desired strength / elongation / heat.
  • it can be subjected to a cutting step or a subsequent extraction step via a stretching step or a heat treatment step.
  • the stretching process may be a separate stretching method in which spinning and stretching are performed in separate steps, or a straight stretching method in which stretching is performed immediately after spinning in one process may be used.
  • the composite fiber is cut so that the ratio (L / D) of the fiber length (L) to the island diameter (D) is in the range of 100 to 2,500.
  • Such cutting is preferably performed with a guillotine cutter, a rotary cutter, or the like using undrawn yarn or drawn yarn as it is or with a tow bundled in units of tens to millions.
  • you may cut in the process after the following extraction process (alkali weight reduction process).
  • the ratio of fiber to alkaline solution is preferably 0.1 to 5%, more preferably 0.4 to 3%. If it is less than 0.1%, the contact between the fiber and the alkaline liquid is large, but the processability such as drainage may be difficult. On the other hand, if it exceeds 5%, the amount of fibers is too large, so that the fibers may be entangled during alkali weight reduction processing.
  • alkali weight loss may be insufficient.
  • the island components may be reduced.
  • the treatment temperature during alkali weight reduction processing is usually about 50 to 90 ° C., preferably about 60 to 80 ° C.
  • sodium hydroxide etc. are mentioned as an alkali used for an alkali weight reduction process.
  • the alkali concentration is preferably 2% to 10%. If it is less than 2%, the alkali is insufficient, and the weight loss rate may be extremely slow. On the other hand, if it exceeds 10%, the alkali weight loss is excessive, and there is a risk that the weight is reduced to the island portion.
  • the cut (or uncut) composite fiber is put into an alkaline solution, treated under a predetermined condition and time, once subjected to a dehydration step, and then put into water again.
  • the method of dehydrating after that is mentioned.
  • the former can be manufactured in a small amount because it is processed in a batch manner, while the neutralization process takes time, and therefore the productivity is slightly poor.
  • the latter can be produced semi-continuously, but requires a large amount of aqueous acid solution and a large amount of water for dilution during the neutralization treatment.
  • the treatment equipment is not limited in any way, but from the viewpoint of preventing fiber dropping during dehydration, the opening ratio (the area of the opening per unit area) as disclosed in Japanese Patent No. 3678511 is 10. It is preferable to apply a mesh-like material (for example, non-alkaline hydrolyzable bag, etc.) of about 50%. If the opening ratio is less than 10%, the moisture loss is extremely poor. On the other hand, if it exceeds 50%, the fibers may fall off. Further, after alkali weight reduction processing, a dispersing agent (for example, model YM-81 manufactured by Takamatsu Yushi Co., Ltd.) is added to the fiber surface in order to enhance dispersibility, and 0.1 to 5.0 wt. % Adhesion is preferred.
  • a dispersing agent for example, model YM-81 manufactured by Takamatsu Yushi Co., Ltd.
  • the sea-island type composite fiber is converted into nanofibers made of the island component.
  • an island component consists of polyester
  • a nanofiber turns into a polyester fiber.
  • the ratio of the short cut nanofibers to the total weight of the filter medium is 0.5 to 20% by weight, preferably 2 to 20% by weight, and more preferably 3 to 10% by weight. If it is less than 0.5% by weight, not only a satisfactory collection efficiency cannot be obtained, but also texture spots as a wet nonwoven fabric may be produced, which is not preferable. On the other hand, if it exceeds 20% by weight, the filter medium (wet non-woven fabric) becomes too dense, so the drainage in the papermaking process becomes extremely poor, the productivity deteriorates, and the pressure loss becomes too large. Absent.
  • the core-sheath composite binder fiber is contained in addition to the short-cut nanofiber, because the structure of the filter medium is maintained.
  • the core-sheath composite binder fiber is preferably a core-sheath composite binder fiber having a single fiber diameter of 5 ⁇ m or more, preferably 5 to 20 ⁇ m, more preferably 7 to 15 ⁇ m.
  • the single fiber diameter of the core-sheath composite binder fiber is less than 5 ⁇ m, the rigidity of the fiber itself is lowered, and the structure of the filter medium for the filter may be difficult to maintain.
  • the number of binder fibers constituting the filter medium for the filter is reduced, which may reduce the adhesion point and lower the rigidity.
  • the fiber length of the core / sheath composite binder fiber is preferably cut to 3 to 100 mm. Further, the core-sheath composite binder fiber is 60 wt% or less, preferably 20 to 40 wt% in the filter medium of the present invention.
  • a polymer in which a polymer having a melting point lower by 40 ° C. or more than the polymer forming the short-cut nanofiber is arranged on the surface as a heat fusion component is preferable.
  • the polymer arranged as the heat fusion component include polyurethane elastomers, polyester elastomers, inelastic polyester polymers and copolymers thereof, polyolefin polymers and copolymers thereof, polyvinyl alcohol polymers, and the like. be able to.
  • polyurethane elastomers include low melting point polyols having a molecular weight of about 500 to 6,000, such as dihydroxy polyether, dihydroxy polyester, dihydroxy polycarbonate, dihydroxy polyester amide, and the like, and organic diisocyanates having a molecular weight of 500 or less, such as p, p.
  • these polymers particularly preferred is a polyurethane using polytetramethylene glycol, poly- ⁇ -caprolactam or polybutylene adipate as a polyol.
  • Polyester elastomers include polyether ester copolymers obtained by copolymerizing thermoplastic polyester as a hard segment and poly (alkylene oxide) glycol as a soft segment, and more specifically, terephthalic acid, isophthalic acid, phthalate.
  • Acids alicyclic dicarboxylic acids such as naphthalene-2,6-dicarboxylic acid, naphthalene-2,7-dicarboxylic acid, diphenyl-4,4′-dicarboxylic acid, 1,4-cyclohexanedicarboxylic acid, succinic acid, oxalic acid , At least one dicarboxylic acid selected from aliphatic dicarboxylic acids such as adipic acid, sebacic acid, dodecanedioic acid and dimer acid, or ester-forming derivatives thereof, 1,4-butanediol, ethylene glycol trimethylene glycol , Tetramethylene glycol An aliphatic diol such as pentamethylene glycol, hexamethylene glycol, neopentyl glycol, decamethylene glycol, or an alicyclic diol such as 1,1-cyclohexanedimethanol, 1,4-cyclohexanedimethanol
  • block copolymer polyether esters having polybutylene terephthalate as a hard component and polyoxybutylene glycol as a soft segment are preferable.
  • the polyester portion constituting the hard segment is polybutylene terephthalate in which the main acid component is terephthalic acid and the main diol component is a butylene glycol component.
  • a part of this acid component (usually 30 mol% or less) may be substituted with another dicarboxylic acid component or an oxycarboxylic acid component, and similarly a part of the glycol component (usually 30 mol% or less). May be substituted with a dioxy component other than the butylene glycol component.
  • the polyether portion constituting the soft segment may be a polyether substituted with a dioxy component other than butylene glycol.
  • Copolyester polymers include aliphatic dicarboxylic acids such as adipic acid and sebacic acid, aromatic dicarboxylic acids such as phthalic acid, isophthalic acid and naphthalenedicarboxylic acid and / or fats such as hexahydroterephthalic acid and hexahydroisophthalic acid.
  • a co-polymer containing a predetermined number of cyclic dicarboxylic acids and aliphatic or alicyclic diols such as diethylene glycol, polyethylene glycol, propylene glycol, and paraxylene glycol, with addition of oxyacids such as parahydroxybenzoic acid as desired.
  • Polymerized esters and the like can be mentioned.
  • polyester obtained by adding and copolymerizing isophthalic acid and 1,6-hexanediol in terephthalic acid and ethylene glycol can be used.
  • the polyolefin-based polymer include low-density polyethylene, high-density polyethylene, polypropylene, and modified products thereof.
  • polyester is disposed in the core and low melting point polyester is disposed in the sheath from the viewpoint of adhesiveness with short cut nanofibers and processability (dispersibility, etc.) in the papermaking process. More preferably.
  • various stabilizers In the above-mentioned polymer, various stabilizers, ultraviolet absorbers, thickening and branching agents, matting agents, coloring agents, and other various improving agents may be blended as necessary.
  • polyester is arranged in the core and low melting point polyester in the sheath. Is more preferable.
  • the heat fusion component occupies at least a half of the surface area.
  • the weight ratio is suitably in the range of 10/90 to 70/30 in terms of the composite ratio (weight ratio) of the heat fusion component and the counterpart component.
  • the form of the core-sheath composite binder fiber is a core-sheath type. In this core-sheath-type core-sheath composite binder fiber, the heat-sealing component is the sheath and the counterpart component is the core, but the core may be concentric or eccentric.
  • various synthetic fibers polyethylene terephthalate, polytrimethylene terephthalate, nylon, olefin-based, aramid-based), wood pulp, and linter pulp as the fibers other than the short-cut nanofiber and the binder fiber.
  • Natural pulp such as a synthetic pulp having aramid or polyethylene as a main component can be used.
  • polyethylene terephthalate short fibers made of drawn polyethylene terephthalate having a single fiber diameter of 2 to 30 ⁇ m and a fiber length of 3 to 10 mm are preferable from the viewpoint of dimensional stability and the like.
  • a desirable ratio of the other fibers is 80% by weight or less, more preferably 60 to 80% by weight in the filter medium.
  • the filter medium preferably has a two-layer structure, and in that case, the short cut nanofiber is preferably included in only one of the two layers.
  • the layer containing the short cut nanofibers is a high density layer, and the other layer is a low density layer.
  • the multilayer filter medium for a filter of the present invention when used as a filter, it is preferable that the high-density layer containing the short cut nanofiber is disposed on the fluid outflow side (clean side).
  • the layer containing the short cut nanofiber is arranged on the fluid outflow side (clean side), it plays a role of collecting minute dust.
  • the basis weight is preferably 30 to 300 g / m 2 , more preferably 50 to 250 g / m 2 , and particularly preferably 80 to 200 g / m 2 .
  • the thickness is preferably 0.5 to 2.0 mm.
  • the density is preferably 0.05 to 0.3 g / cm 3 .
  • the high-density layer containing short cut nanofibers preferably has a basis weight of 10 to 140 g / m 2 , more preferably 20 to 120 g / m 2. Particularly preferably, it is 30 to 80 g / m 2 , and its thickness is 0.2 to 1.8 mm.
  • the low density layer not containing short cut nanofibers preferably has a basis weight of 20 to 160 g / m 2 , more preferably 30 to 130 g / m 2 , particularly preferably 50 to 80 g / m 2 , and The thickness is 0.3 to 2.2 mm.
  • the basis weight ratio of the two layers is 10 to 60% by weight, preferably 20% by weight of the high-density layer containing short cut nanofibers.
  • a normal long net paper machine, a short net paper machine, a circular net paper machine, or a combination of a plurality of these can be used, and (1) No. 1 Paper is made using the slurry for one layer. (2) The slurry for the second layer is added until the paper making process is completed. (3) The paper making process for the second layer is completed if necessary.
  • a method of manufacturing by adding a slurry for the third layer and repeating a similar process as necessary to make a wet nonwoven fabric by making a paper into a multilayer structure and then heat-treating is preferable.
  • paper making using the slurry for the first layer, and (2) adding the slurry for the second layer before the paper making step is completed means that the paper making of (1)
  • the water in the slurry supplied to the papermaking in the process is about 40% or more, preferably 50 to 70%
  • the slurry in the process (2) is additionally charged, and (3)
  • the slurry for the next step may be added in the same manner even after the step.
  • the heat treatment step either a Yankee dryer or an air-through dryer is possible after the paper making step.
  • the heat treatment temperature is usually 100 to 140 ° C., preferably 110 to 130 ° C.
  • the heat treatment time is usually about 30 to 300 seconds, preferably about 60 to 180 seconds.
  • the filter medium has a multilayer structure of two or more layers, and no boundary surface exists between two adjacent layers of the multilayer structure.
  • the remaining 8 points excluding the maximum and minimum values
  • the ratio of the maximum value / minimum value is preferably 1.5 or more (more preferably 1.5 to 2.5).
  • the absence of the interface between the layers makes it possible to obtain a filter having high collection efficiency and low pressure loss and having a long filter life.
  • the reason for this is that when each layer is made separately and then laminated, the smaller the basis weight, the greater the density due to the paper making, so the pressure loss of the wet nonwoven fabric (filter material) after lamination increases, as described above.
  • the slurry for the second layer is additionally added to make a wet nonwoven fabric (filter medium) (in the case of two layers), so the density does not increase, so the pressure loss
  • the present inventors presume that this is not high.
  • the short cut nanofibers are arranged in one layer, and the other layers do not contain the short cut nanofibers. It is preferable to create a density difference between the layers because it is possible to obtain a filter having a higher collection efficiency and a lower pressure loss and a longer filter life.
  • a measure for measuring the density difference between the layers when the number of fibers on the surface where many fibers are exposed on both surfaces of the filter medium is DL, and the number of fibers on the other surface where few fibers are exposed is DU, DU
  • the ratio of / DL is preferably 0.8 or less (more preferably 0.1 to 0.8).
  • the ratio of DU / DL exceeds 0.8 and approaches 1 with no density difference, the density difference between the layers decreases, and it has high collection efficiency and low pressure loss and has a long filter life.
  • the DL and DU are measured by the following method. That is, after each surface of the filter medium is photographed at 100 times using a scanning electron microscope, a straight line is drawn and the number of fibers (all visible fibers) crossing the straight line is counted.
  • a sheet-like structure such as a woven or nonwoven fabric having a rough structure (air permeability of 100 cc / cm 2 / s or more) that does not affect the filter performance is laminated to improve rigidity.
  • the sheet-like structure may be provided on either side of the filter medium, but is usually preferably provided on the surface of the low-density layer that does not contain short cut nanofibers.
  • the shape of the filter medium is not limited to a flat plate shape, and may be any shape.
  • known functional processing such as ordinary water repellent processing, flameproof processing, flame retardant processing, dyeing processing, and negative ion generation processing may be added.
  • the filter of the present invention is a filter using the above filter medium.
  • the low density layer On the fluid inflow side (dust side).
  • a high density layer containing short cut nanofibers
  • cleaning side the fluid outflow side
  • the filter of the present invention Since the filter of the present invention has high collection efficiency and low pressure loss, and has a long filter life, it can be suitably used as an air filter for an intake internal combustion engine.
  • the total basis weight of such a filter is usually about 30 to 300 g / m 2 , preferably 50 to 250 g / m 2 , particularly preferably about 80 to 200 g / m 2 .
  • SEM scanning electron microscope
  • TAPPI manufactured by
  • Example 4 A sheet was obtained under the same conditions as in Example 1, except that the basis weight of the upper layer was 75 g / m 2 , the basis weight of the lower layer was 75 g / m 2 , and the total basis weight was 150 g / m 2 . .
  • the obtained physical properties are shown in Table 1.
  • Example 1 Each of the slurries used in Example 1 was separately made using TAPPI to obtain wet paper, and then laminated, and after laminating, a drying process similar to Example 1 was obtained to obtain a sheet (different two layers) Combined). The obtained physical properties are shown in Table 1.
  • a filter medium and a filter using the filter medium are provided.
  • an air filter for an internal combustion engine such as an air filter for an intake internal combustion engine, an air conditioner for an indoor air conditioner, an air conditioner, a heater (electric type, kerosene type) Etc.), automobile air conditioners, air purifiers, clean rooms, indoor humidifiers, and other filters, microfilters, and liquid filters, and their industrial value is extremely high.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Filtering Materials (AREA)
  • Nonwoven Fabrics (AREA)

Abstract

L'invention concerne : un matériau de filtration pour un filtre, le matériau de filtration permettant au filtre d'avoir un haut rendement de capture, une faible perte de pression et une longue durée de vie ; un procédé de fabrication du matériau de filtration pour un filtre ; et un filtre formé à l'aide du matériau de filtration pour un filtre. Un matériau de filtration pour un filtre est utilisé comme élément pour la constitution du filtre et comprend un tissu non tissé humide. Le matériau de filtration pour un filtre a une structure multicouches ayant au moins deux couches et est configuré de telle sorte qu'il n'y ait pas de surface de délimitation présente entre les deux couches.
PCT/JP2012/074503 2011-12-19 2012-09-25 Matériau de filtration pour un filtre, son procédé de fabrication, et filtre WO2013094268A1 (fr)

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CN201280062717.8A CN104066491B (zh) 2011-12-19 2012-09-25 过滤器用滤材及其制造方法以及过滤器
EP12860820.5A EP2796180B1 (fr) 2011-12-19 2012-09-25 Matériau de filtration pour un filtre, son procédé de fabrication, filtre et utilisation
US14/362,727 US10550803B2 (en) 2011-12-19 2012-09-25 Filter medium for filter, method for producing the same, and filter

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JP2011277014A JP5865058B2 (ja) 2011-12-19 2011-12-19 フィルター用ろ材およびその製造方法、ならびにフィルター
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CN111495054B (zh) * 2015-11-19 2022-03-04 帝人富瑞特株式会社 袋式过滤器用过滤布及其制造方法和袋式过滤器
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JP2017196581A (ja) * 2016-04-28 2017-11-02 株式会社マーレ フィルターシステムズ フィルタ用の濾材の製造方法
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US10550803B2 (en) 2020-02-04
EP2796180A4 (fr) 2015-11-11
JP2013126626A (ja) 2013-06-27
JP5865058B2 (ja) 2016-02-17
EP2796180A1 (fr) 2014-10-29
CN104066491B (zh) 2016-09-28
CN104066491A (zh) 2014-09-24
US20140360145A1 (en) 2014-12-11

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